Modeling Compound

ABSTRACT

A modeling compound and methods for making the same are described. The modeling compound, in some embodiments, comprises about 20% to about 40% by weight starch-based binder, and about 0.15% to about 1.2% by weight microspheres dispersed throughout the compound.

RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/446,413, filed on Apr. 13, 2012, the entirety of which is herebyincorporated herein by reference for the teachings therein.

BACKGROUND

1. Field

This patent specification relates to compositions, methods of making andmethods of using modeling compounds. More particularly, this patentspecification relates to compositions, methods of making and methods ofusing starch-based modeling compounds containing microspheres.

2. Background

Starch and water based dough have several disadvantages for use bychildren and artists. Starch and water based dough usually exhibit poorplasticity, and substantial shrinking upon drying. Other drawbacksinclude poor extrudability, limiting the use of extrusion tools and theshapes that can be created.

SUMMARY

Aspects of the present disclosure relate to a modeling compositioncomprising a starch-based binder, water, a retrogradation inhibitor andmicrospheres. According to some embodiments, the modeling compositioncan further comprises a surfactant. According to some embodiments, themodeling composition can further comprise a lubricant, salt, and apreservative.

According to some embodiments, the modeling composition can compriseabout 30% to about 60% by weight water, about 20% to about 40% by weightstarch-based binder, about 2.0% to about 5.0% by weight lubricant, about0.5% to about 4.0% by weight surfactant, about 5% to about 20% by weightsalt, about 0.1% to about 1% by weight preservative, about 0.5% to about5% by weight retrogradation inhibitor, 0% to about 1% by weighthardener, about 0.15% to about 1.2% by weight microspheres, 0% to about10% by weight humectant, 0% to about 0.5% by weight fragrance, and 0% toabout 3.5% by weight colorant.

According to some embodiments, the microspheres can be selected from thegroup consisting of one of pre-expanded microspheres, glassmicrospheres, or some combination thereof. The microspheres can behollow microspheres, solid microspheres or some combination thereof. Themicrospheres can have a size ranging from 90 micron to 130 microns.

According to some embodiments, the starch-based binder can comprisegelatinized starch. According to some embodiments, the starch-basedbinder can be selected from a group consisting of one of wheat flour,rye flour, rice flour, tapioca flour or some combination thereof.

According to some embodiments, the salt can be selected from the groupconsisting of one of sodium chloride, calcium chloride, potassiumchloride or some combination thereof. According to some embodiments, thelubricant can be selected from the group consisting of one of mineraloil, vegetable oil, triglycerides or some combination thereof. Accordingto some embodiments, the retrogradation inhibitor can compriseamylopectin. For example, the retrogradation inhibitor can be selectedfrom the group consisting of one of waxy corn starch, waxy rice starch,waxy potato starch or some combination thereof. According to someembodiments, the surfactant can be selected from the group consisting ofone of polyethylene glycol esters of oleic acid, polyethylene glycolesters of stearic acid, polyethylene glycol esters of palmitic acid,polyethylene glycol esters of lauric acid, ethoxylated alcohols, blockco-polymer of ethylene oxide, block co-polymer of propylene oxide orsome combination thereof. According to some embodiments, thepreservative is selected from the group consisting of one of calciumpropionate, sodium benzoate, potassium sorbate, methyl paraben, ethylparaben, butyl paraben or some combination thereof. According to someembodiments, the hardener can be selected from the group consisting ofone of sodium aluminum sulfate, potassium aluminum sulfate, aluminumammonium sulfate, aluminum sulfate, ammonium ferric sulfate or somecombination thereof. According to some embodiments, the acidulant can beselected from the group consisting of one of citric acid, alum,potassium dihydrogen sulphate or some combination thereof.

Aspects of the present disclosure relate to a method of preparing astarch-based modeling compound. According to some embodiments, themethod comprises providing a mixer, adding in the mixer and mixing about30% to about 60% by weight water, about 20% to about 40% by weightstarch-based binder, about 2.0% to about 5.0% by weight lubricant, about0.5% to about 4.0% by weight surfactant, about 5% to about 20% by weightsalt, about 0.1% to about 1% by weight preservative, about 0.5% to about5% by weight retrogradation inhibitor, 0% to about 1% by weighthardener, about 0.15% to about 1.2% by weight microspheres, 0% to about10% by weight humectant, 0% to about 0.5% by weight fragrance, and 0% toabout 3.5% by weight colorant.

According to some embodiments, the ingredients can be mixed to form afirst mixture prior to adding water to the first mixture, and the watercan be heated prior to adding the water to the first mixture.

Further features and advantages will become more readily apparent fromthe following detailed description when taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is further described in the detailed descriptionwhich follows, in reference to the noted plurality of drawings by way ofnon-limiting examples of exemplary embodiments, and wherein:

FIG. 1 shows a viscosity curve in accordance with some embodiments;

FIG. 2 shows a viscosity curve in accordance with some embodiments; and

FIG. 3 shows molded objects in accordance with some embodiments.

While the above-identified drawings set forth presently disclosedembodiments, other embodiments are also contemplated, as noted in thediscussion. This disclosure presents illustrative embodiments by way ofrepresentation and not limitation. Numerous other modifications andembodiments can be devised by those skilled in the art which fall withinthe scope and spirit of the principles of the presently disclosedembodiments.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description provides exemplary embodiments only, and isnot intended to limit the scope, applicability, or configuration of thedisclosure. Rather, the following description of the exemplaryembodiments will provide those skilled in the art with an enablingdescription for implementing one or more exemplary embodiments. It beingunderstood that various changes may be made in the function andarrangement of elements without departing from the spirit and scope ofthe invention as set forth in the appended claims.

Specific details are given in the following description to provide athorough understanding of the embodiments. However, it will beunderstood by one of ordinary skill in the art that the embodiments maybe practiced without these specific details. For example, systems,processes, and other elements in the invention may be shown ascomponents in block diagram form in order not to obscure the embodimentsin unnecessary detail. In other instances, well-known processes,structures, and techniques may be shown without unnecessary detail inorder to avoid obscuring the embodiments. Further, like referencenumbers and designations in the various drawings indicated likeelements.

Also, it is noted that individual embodiments may be described as aprocess which is depicted as a flowchart, a flow diagram, a data flowdiagram, a structure diagram, or a block diagram. Although a flowchartmay describe the operations as a sequential process, many of theoperations can be performed in parallel or concurrently. In addition,the order of the operations may be re-arranged. A process may beterminated when its operations are completed, but could have additionalsteps not discussed or included in a figure. Furthermore, not alloperations in any particularly described process may occur in allembodiments. A process may correspond to a method, a function, aprocedure, a subroutine, a subprogram, etc. When a process correspondsto a function, its termination corresponds to a return of the functionto the calling function or the main function.

Furthermore, embodiments of the invention may be implemented, at leastin part, either manually or automatically. Manual or automaticimplementations may be executed, or at least assisted, through the useof machines, hardware, software, firmware, middleware, microcode,hardware description languages, or any combination thereof. Whenimplemented in software, firmware, middleware or microcode, the programcode or code segments to perform the necessary tasks may be stored in amachine readable medium. A processor(s) may perform the necessary tasks.

Aspects of the present disclosure relate to starch-based modelingcompounds and a method for preparing starch-based modeling compound. Asused herein, the terms “modeling compound” and “modeling dough” are usedinterchangeably.

The starch or starch-based binder defining the matrix of the modelingcompound can be selected from, for example, wheat flour, rye flour, riceflour, tapioca flour, and the like and combinations thereof. Starch isthe primary source of stored energy in cereal grains. Starches arecomposed primarily of amylose, a comparatively low molecular weightstraight-chain carbohydrate, and/or amylopectin, a branched carbohydratehaving a much higher molecular weight and, in solution, a higherviscosity. For example, wheat starch contains about 25% amylose andabout 75% amylopectin; and tapioca starch contains about 17% amylose andabout 83% amylopectin. (Percentages herein refer to percentage byweight, unless otherwise specified). Waxy starches contain at leastabout 90% amylopectin. Waxy corn starch, for example, contains less thanabout 1% amylose and greater than about 99% amylopectin.

Amylose and amylopectin do not exist free in nature, but as componentsof discrete, semicrystalline aggregates called starch granules. It isthe crystalline regions that give the starch granule its structure andfacilitate identification of uncooked starch.

The presence of numerous hydroxyl groups in starch allows for thehydration of starch through hydrogen bonding. For example, amylose canbe dissolved for example by heating in water at 150° C.-160° C., underpressure. The hydration process in presence of heat produces a change inthe structure of the starch granule. The starch-starch molecularinteractions are disrupted and replaced by starch-water interactions.When an aqueous starch dispersion is heated, gelatinization occurs,during which the crystal structure of starch granules is disrupted, andthe starch granules absorb water and hydrate, and produces a viscoushydrocolloidal solution. As used herein, the term “gelatinization”refers to the disruption of molecular orders within the starch granule,manifested in changes in properties such as granular swelling, nativecrystallite melting, loss of birefringence, and starch solubilization.Starch gelatinization generally refers to the process that breaks downthe association of starch molecules, in the presence of water and heat.The penetration of water, which acts as a plasticizer, and formation ofhydrogen bonding with water decreases the number of and size ofcrystalline regions of starch granules.

In some embodiments, the starch-based modeling dough includesgelatinized starch. There is a need for a starch-based modeling compoundthat has a soft, flexible texture, low viscosity, is not sticky, andresists retrogradation and hardening over time.

Amylose fractions will upon cooling form crystalline aggregates byhydrogen bonding or retrogradation. Retrogradation is a processinvolving reassociation of starch molecules that occurs after afreshly-made starch gel is cooled. During retrogradation, stablehydrogen bonding forms between linear segments of amylose producing anaggregate or gel network, which can depend upon the concentration ofamylose in the product.

Amylopectin starch is known to be resistant to retrogradation. However,when amylopectin is mixed with water and heated, it tends to form apaste having a sticky texture, rather than a soft gel, which is desiredfor a modeling compound. A sticky texture in a modeling compound causesthe modeling compound to be messy for the user to manipulate, as thecompound is more likely to stick to hands, molds, toys, furniture, andcarpeting.

The processes of gelatinization and retrogradation affect thecharacteristics of starch-containing products, such as starch-basedmodeling compounds. During manufacturing of starch-based modelingcompounds, gelatinization occurs, forming modeling compounds that aresoft, and easy to manipulate and shape, due to their soft texture andlow viscosity. However, retrogradation begins to occur shortly aftermanufacturing, and is usually well advanced in as little as 48 hours.Retrogradation causes significant hardening of starch-based modelingcompounds and increases viscosity. The hardening and increasing ofviscosity of the modeling compounds is undesirable because the hardenedcompounds are more difficult to manipulate and shape, particularly byyoung children.

Accordingly some aspects of the present disclosure refer to starch-basedmodeling compound that is soft, flexible, extrudable, has a lowviscosity, and is not sticky. In some embodiments, the modeling compoundcomprises from about 20 weight percent to about 50 weight percent ofstarch-based binder. In some embodiments, the starch-based bindercomprises gelatinized starch. For example, the starch-based binder cancomprise starch that is at least 50%, at least 75%, at least 95%gelatinized starch.

In some embodiments, the starch-based modeling compound comprises aretrogradation inhibitor. For example, the modeling compound cancomprises up to 5, or up to 10 weight percent retrogradation inhibitor.In some embodiments, the starch-based modeling compound comprises from0.5 weight percent to 7.5 weight percent retrogradation inhibitor. Theretrogradation inhibitor can comprise amylopectin. The retrogradationinhibitor can comprise a waxy starch. For example, the retrogradationinhibitor can be selected from waxy corn starch, waxy rice starch, waxypotato starch and combinations thereof.

Generally, air-dryable starch-based modeling compounds have a tendencyto crack, flake, crumble and shrink upon drying. Because water contentis relatively high in the wet stage of the dough, water loss upondrying, results in a commensurate volume loss in the finished moldedpiece. In addition, since wet, starch-based modeling compounds have arelatively low plasticity and high rheological values, it can bedifficult for the users to extrude and can limit the users in the rangeof designs, shapes that can be created.

Aspects of the present disclosure relate to a starch-based modelingcompound with high degree of plasticity, ductility and extrudabilitywhen wet and low tendency to crack and limited volume shrinkage upondrying. Such modeling compounds may be used by small children andartists in general. In some embodiments, the modeling compound disclosedherein may be used using extrusion apparatus to form a variety ofshapes, articles or artwork.

As used herein the term “viscosity” refers to the measure of theinternal friction of a fluid, i.e. when a layer of fluid is made to moverelative to another layer. The greater the friction the greater theamount of force required to cause this movement also referred herein asshear. Shearing occurs when the fluid is physically moved by pouring,spreading, mixing, etc. In general, viscosity is proportional to theforce necessary to cause a substance to flow.

It will be appreciated that the modeling compounds disclosed herein canhave pseudoplastic properties. As such, the modeling compounds describedherein can have the capability of changing apparent viscosity with achange in shear rate. For example, the viscosity of the modelingcompound described herein can increase when the shear rate decreases andvice versa.

It is also understood that the modeling compounds described herein canbe thixotropic, that is that the viscosity of the modeling compounds candecrease when shear rate is constant.

The rheological properties of the modeling compounds can be achieved byvarying the starch binder, the filler, the retrogradation inhibitor, thesurfactant, the water and other components relative to one another andtheir relative proportion. Desirable rheological properties of themodeling compounds include, among others, pliability, extrudability, andreduced viscosity. For example, water content, and productiontemperature can have a significant impact on the viscosity of themodeling compound. Addition of microspheres, retrogradation inhibitor,surfactant and any combinations of any of the foregoing can also have asignificant impact on the viscosity and extrudability of the modelingcompound.

Additional desirable properties of the modeling compounds include, butare not limited to, for example, color stability, long usage time andstorage stability.

According to some embodiments, the starch-based modeling compound cancomprise (1) about 30% to about 60% by weight of water; (2) about 5% toabout 20% by weight of salt; (3) about 2.0% to about 5% by weight oflubricant; (4) 0.5% to about 4.0% by weight of surfactant; (5) about 20%to about 40% by weight of starch-based binder; (6) 0.5% to about 5% byweight of retrogradation inhibitor; (7) 0.1% to about 1% by weight ofpreservative and (8) about 0.15% to about 1.2% by weight ofmicrospheres.

In some embodiments, the composition can include up to about 1% byweight of hardener; up to about 10% by weight of humectant; up to about0.5% by weight of fragrance; and up to about 3.5% by weight of colorant.

Microspheres

According to some embodiments, the modeling compound comprisesmicrospheres. The microspheres can be solid or hollow. For example, themodeling compound comprises hollow microspheres that can be dispersed asfiller in the modeling compound comprising starch as a matrix. In someembodiments, the modeling composition comprises from about 0.15 weightpercent to about 1.2 weight percent of microspheres. As used herein, theterm “microsphere” relates to non-toxic particles having a spherical orgenerally spherical shape with a diameter ranging from about 1 micron toabout 100 microns, or from 1 to about 500 microns, or from 1 to about1,000 microns. In some embodiments, the microspheres used in thecomposition have a particle size ranging from about 30 to about 60, fromabout 30 to about 100, from about 30 to about 150, from about 90 micronsto about 130 microns. Microspheres with larger diameter may be used andmay be desirable depending on the desired consistency of the modelingcompound.

Examples of microspheres include, but are not limited to, ceramicmicrospheres, silica alumina alloy microspheres, plastic microspheres,glass microspheres and combinations thereof. An example of glassmicrospheres may include those made of soda lime borosilicate glass orthe like such as Scotchlite™ Type K or S, for example K-25, from 3MCorporation. An example of ceramic microspheres may include fly ashmicrospheres or the like, such as Zeospheres from 3M Corporation. Anexample of thermoplastic microspheres include those made ofacrylonitrile/vinylidene chloride copolymers from Akzo-Nobel, such asExapancel® DE microspheres (such as Exapancel® 920DET40d25) andacrylonitrile copolymer microspheres from Matsumoto (such as Micropearl®F-80DE). In some embodiments, a mixture of more than one glass, ceramic,thermoplastic, and thermoset plastic microspheres can be used to obtainone or more desired mechanical properties.

Hollow plastic microspheres can be made from a variety of materials andare generally available in sizes ranging from 10 to 1000 micron diameterand densities ranging from 0.022 to 0.2 g/cc. Any of these materials, orcombination of such materials, may be employed for the purpose ofachieving particular combination of properties.

In some embodiments, pre-expanded microspheres having an acrylonitrilecopolymer shell encapsulating volatile hydrocarbon are used. Thecopolymer shell can comprise various copolymers selected from, but notlimited to, polyvinyldiene chloride, acrylonitrile, and acrylic ester.Such microspheres can have a size ranging from 90 to 130 microns and atrue specific gravity of 0.022.

The low density of hollow microspheres can reduce the overall density ofthe dough comprising the hollow microspheres since water and the rest ofthe components have much higher densities. Microspheres remain intactduring the manufacturing process because mixing and pumping equipment donot exert enough force to fracture them.

In some embodiments, the composition of the modeling compound has aconcentration of microspheres ranging from about 0.15% to about 1.2% byweight. In some embodiments, up to 2%, up to 3%, up to 4%, up to 5%, upto 6% by weight. In some embodiments, the weight content of hollowmicrosphere can be optimized according to a desired property of themodeling compound, such as ease of formability, ease of extrusion,stickiness, shape preservation etc. According to some embodiments, themicrospheres can make from about 20% to about 25% of the volume of themodeling compound due to the low actual partial volume of the water.While the weight percent of the water in the modeling compound can behigh (e.g. from about 30% to about 60%), the actual partial volume ofthe water is relatively low due to the relatively high density of thewater (1.0 g/cc) and the low density of the microspheres. For example,the microspheres can occupy about 22% of the modeling compound byvolume. As a result, upon evaporation of the water during the dryingstep, the modeling dough made with microspheres shrinks less thanmodeling dough made without microspheres, resulting in improved shapepreservation and dimensional stability of the molded shape.

In some embodiments, the modeling composition comprising microspherescan change the mechanical properties resulting in a starch-basedmodeling compound being softer, more flexible, easier to extrude andhaving low viscosity. For instance, the starch-based modeling compoundcomprising microspheres and retrogradation inhibitor can have aviscosity of, for example, from about 250 Pascal seconds to about 500Pascal seconds, in comparison to a starch-based compound includingretrogradation inhibitor but not including microspheres, which can havea viscosity of, for example, from about 1,300 Pascal seconds to about1,500 Pascal seconds (See FIG. 1).

Due to the shape and size of the microspheres, the microspheres canoffer a ball-bearing effect and the space that is not occupied by themicrospheres can accommodate water and the other components of themodeling compound mixture so as to be movable during modeling.

Furthermore, such compositions make the modeling compound easier to use.For example, extrusion force that needs to be applied by the users whenusing extrusion device can be significantly reduced. Such modelingcompounds can be used to form a variety of shapes (such as geometric andnon-geometric shapes, linear and non-linear shapes, etc,), articles orartwork. These modeling compounds may be molded with tools, by hand, bymolds or using extrusion devices to form a variety of shapes, articlesor artwork, as noted above. Artists can use extrusion devices to fashionmodeling compounds into a wide variety of desirable shapes, such as,animals, flowers, artwork or to form fanciful designs and the like.Examples of tools, include, but are not limited to, a decorating gun, aribbon extruder tool, hand held food extruder and the like to createdesigns, and decorations, such as cake decoration. In addition, themodeling compound can be used in a pen-like device or any device capableof applying the modeling compound onto a surface, such as paper, toproduce art like effects.

In some embodiments, the microspheres appear white so as not interferewith the coloration to the modeling compound.

The water generally meets the National Primary Drinking WaterSpecifications. In some embodiments, the modeling compound comprisesfrom about 30 weight percent to about 60 weight percent of water. Watercan act as a plasticizer, to increase the plasticity of the modelingcompound.

The salt can be selected from, for example, sodium chloride, calciumchloride, and potassium chloride. The presence of the salt can reduceamount of water needed for hydration for starch. In some embodiments,the salt can provide the modeling compound with antimicrobialcharacteristics. In some embodiments, the modeling compound comprisesfrom about 5 weight percent to about 20 weight percent of salt.

A preservative can also be added to increase the shelf life of themodeling compound. The preservative can be selected from, for example,calcium propionate, sodium benzoate, potassium sorbate, methyl paraben,ethyl paraben, butyl paraben, and combinations thereof. The preservativecan also be any other appropriate preservative known to those skilled inthe art, such as one or more preservative compounds that inhibit moldgrowth at a pH of less than about 4.5, used alone or in combination.

The lubricant can be selected from, for example, mineral spirits,mineral oil, vegetable oil and combinations thereof. The mineral oil canbe, a triglyceride derived from vegetable oil or caprylic/caprictriglyceride. In some embodiments, the lubricant is a combination ofmineral oil and triglycerides. Such lubricant combination, according tosome embodiments, provides for a less oily modeling compound. Thelubricant can act to prevent the dough from becoming sticky and toimpart softness and smoothness to the dough. Another function of thiscomponent is to facilitate separation of the molded article from thetool used for molding. In some embodiments, the modeling compoundcomprises from about 2 weight percent to about 5 weight percent oflubricant.

The surfactant can be selected from, for example, polyethylene glycolesters of oleic acid (e.g. Tween 80), polyethylene glycol esters ofstearic acid (e.g. Tween 60), polyethylene glycol esters of palmiticacid (e.g. Tween 40), polyethylene glycol esters of lauric acid (e.g.Tween 20), ethoxylated alcohols (for example, Neodol 23-6.5, ShellChemicals), block co-polymer of ethylene oxide or propylene oxide. Insome embodiments, the surfactant has a hydrophilic loophole balance(HLB) of about 12-20. In some embodiments, the surfactant can be anydifunctional block co-polymer surfactant capable of wetting themicrospheres and being hydrophilic. For example, the surfactant can be adifunctional block co-polymer surfactant having a HLB ranging from about1 to about 7. Such properties can allow for plasticization of themodeling compound and can help the microspheres to stay embedded intothe modeling compound. In some embodiments, the modeling compoundcomprises up to 1%, up to 2%, up to 3% or up to about 4% weight ofsurfactant. For example, the modeling compound can comprise 1.2%difunctional block co-polymer surfactant. In some embodiments, thepresence of surfactant can lower the viscosity of the modeling compound.For example, the viscosity of a modeling compound comprising asurfactant, such as for example, 1.2% difunctional block co-polymersurfactant, can be half that of the viscosity of the same compound whichdoes not include the surfactant (FIG. 2). In addition the surfactant canaid the extrusion of the modeling compound.

In some embodiments, the combination of lubricant and surfactant canreduce the stickiness of the starch-based modeling compound. In someembodiments, the lubricant has a low enough viscosity so that themodeling compound does not feel objectionably tacky.

In some embodiments, the modeling compound can include a hardener. Forexample, the modeling compound can include up to 1 weight percent ofhardener. The hardener can be selected from, for example, sodiumaluminum sulfate, potassium aluminum sulfate, aluminum ammonium sulfate,aluminum sulfate, and ammonium ferric sulphate or the like.

In some embodiments, the modeling compound can also include anacidulant. The acidulant can be selected from, for example, citric acid,alum, potassium dihydrogen sulphate or some combinations thereof.However, any known nontoxic acid can be used. The modeling compound canhave a pH of about 3.5 to about 4.5. The modeling compound can have a pHof about 3.8 to about 4.1.

The humectant can be for example, a glycol. Humectants can also reducebrittleness of the dried dough, and slow drying to increase workingtime. Some humectants can also act as a plasticizer, to increase theplasticity of the modeling compound.

The fragrance can be, for example, any water-dispersible oroil-dispersible nontoxic fragrance wherein the fragrance can be eitherpleasing (i.e., flower, food, etc.) or not pleasing (i.e., bitter, etc.)to a human's smell.

A colorant may be included to the modeling compound. The colorant caninclude, for example, any nontoxic dyes, pigments, phosphorescentpigments, or macro-sized particles such, as glitter or pearlescentmaterials.

Methods of Making

According to some aspects of the present disclosure, a method ofpreparing a starch-based modeling compound includes the steps of: (a)providing a mixer; and (b) adding the following ingredients to themixer: (1) about 30% to about 60% by weight of water; (2) about 5% toabout 20% by weight of salt; (3) about 2.0% to about 5% by weight oflubricant; (4) about 0.5% to about 4.0% by weight of surfactant; (5)about 20% to about 40% by weight of starch-based binder; (6) about 0.5%to about 5% by weight of retrogradation agent; (7) about 0.1% to about1% by weight of preservative and (8) about 0.15% to about 1.2% by weightof microspheres; and (c) mixing the ingredients.

In some embodiments, the ingredient can optionally also include up toabout 1% by weight hardener; up to about 10% by weight humectant; up toabout 0.5% by weight fragrance; and up to about 3.5% by weight colorant.

In some embodiments, salt, lubricant, surfactant, starch-based binder,preservative, retrogradation inhibitor, microspheres and optionally,fragrance, colorant, hardener, and humectant can be mixed to form afirst mixture. Water can be heated to sufficiently gelatinize starchbefore being added to the first mixture to form a second mixture. Thetemperature is then cooled at room temperature.

Any suitable mixer known to those skilled in the art can be used, suchas an ordinary bakery dough mixer or any suitable stainless steel mixer.

EXAMPLES

The present disclosure will be described with reference to the followingexample, however the present disclosure is by no means limited to theseexamples.

Example 1 Exemplary Formulation of the Modeling Compounds

Tables 1 through 5 below provide exemplary formulations for the instantstarch-based modeling compound in weight percent of the total compound.

Table 1 provides an exemplary formulation for the instant starch-basedmodeling compound in weight percent of the total compound comprising astarch-based binder, a retrogradation inhibitor such as waxy maizestarch, a difunctional block co-polymer surfactant and pre-expandedmicrospheres.

TABLE 1 Formulation of the modeling compound 1 Modeling Compound 1INGREDIENT Weight Percent SODIUM CHLORIDE 6.067 CALCIUM CHLORIDE 6.067ALUMINUM SULFATE 0.600 POTASSIUM SORBATE 0.300 SODIUM BENZOATE 0.200STARCH-BASED BINDER: FLOUR 30.000 WAXY MAIZE STARCH (C-GEL 04230) 2.333DIFUNCTIONAL BLOCK 1.200 CO-POLYMER SURFACTANT F-80DE MICROPEARL ® 0.600VEGETABLE OIL 1.667 MINERAL OIL 1.667 WATER 49.167 FRAGRANCE 0.033PIGMENT 0.100 TOTAL 100.000

Table 2 provides an exemplary formulation for the instant starch-basedmodeling compound in weight percent of the total compound comprising astarch-based binder, a retrogradation inhibitor such as waxy maizestarch, a conventional non-ionic surfactant and pre-expandedmicrospheres.

TABLE 2 Formulation of the modeling compound 2 Modeling Compound 2INGREDIENT Weight Percent SODIUM CHLORIDE 6.067 CALCIUM CHLORIDE 6.067ALUMINUM SULFATE 0.600 POTASSIUM SORBATE 0.300 SODIUM BENZOATE 0.200STARCH-BASED BINDER: FLOUR 30.000 WAXY MAIZE STARCH (C-GEL 04230) 2.333TWEEN 60 1.200 F-80DE MICROPEARL ® 0.600 VEGETABLE OIL 1.667 MINERAL OIL1.667 WATER 49.167 FRAGRANCE 0.033 PIGMENT 0.100 TOTAL 100.000

Table 3 provides an exemplary formulation for the instant starch-basedmodeling compound in weight percent of the total compound comprising astarch-based binder, a retrogradation inhibitor such as waxy maizestarch, a difunctional block co-polymer surfactant and glassmicrospheres.

TABLE 3 Formulation of the modeling compound 3 Modeling Compound 3INGREDIENT Weight Percent SODIUM CHLORIDE 5.714 CALCIUM CHLORIDE 5.714ALUMINUM SULFATE 1.256 POTASSIUM SORBATE 0.300 SODIUM BENZOATE 0.200STARCH-BASED BINDER: FLOUR 28.258 WAXY MAIZE STARCH (C-GEL 04230) 2.198DIFUNCTIONAL BLOCK 1.130 CO-POLYMER SURFACTANT SCOTHCHLITE ™ GLASSBUBBLES K25 5.652 VEGETABLE OIL 1.570 MINERAL OIL 1.570 WATER 46.313FRAGRANCE 0.031 PIGMENT 0.094 TOTAL 100.000

Table 4 provides an exemplary formulations for the instant starch-basedmodeling compound in weight percent of the total compound comprising astarch-based binder, a retrogradation inhibitor such as waxy maizestarch, a difunctional block co-polymer surfactant and pre-expandedmicrospheres having a diameter from 35 to 55 μm and true density rangingfrom of 0.025 g/cc to 0.25 g/cc.

TABLE 4 Formulation of the modeling compound 4 Modeling Compound 4INGREDIENT Weight Percent SODIUM CHLORIDE 6.067 CALCIUM CHLORIDE 6.067ALUMINUM SULFATE 0.600 POTASSIUM SORBATE 0.300 SODIUM BENZOATE 0.200STARCH-BASED BINDER: FLOUR 30.000 WAXY MAIZE STARCH (C-GEL 04230) 2.333DIFUNCTIONAL BLOCK 1.200 CO-POLYMER SURFACTANT EXPANCEL ® 920DET40d250.600 VEGETABLE OIL 1.667 MINERAL OIL 1.667 WATER 49.167 FRAGRANCE 0.033PIGMENT 0.100 TOTAL 100.000

Table 5 provides an exemplary formulation for the instant starch-basedmodeling compound in weight percent of the total compound comprising astarch-based binder, a retrogradation inhibitor such as waxy maizestarch, a difunctional block co-polymer surfactant, pre-expandedmicrospheres and a humectant.

TABLE 5 Formulation of the modeling compound 5 Modeling Compound 5INGREDIENT Weight Percent SODIUM CHLORIDE 6.067 CALCIUM CHLORIDE 6.067ALUMINUM SULFATE 0.600 POTASSIUM SORBATE 0.300 SODIUM BENZOATE 0.200STARCH-BASED BINDER: FLOUR 30.000 WAXY MAIZE STARCH (C-GEL 04230) 2.333DIFUNCTIONAL BLOCK 1.200 CO-POLYMER SURFACTANT F-80DE MICROPEARL ® 0.600VEGETABLE OIL 1.667 GLYCERIN 3.000 MINERAL OIL 1.667 WATER 46.167FRAGRANCE 0.033 PIGMENT 0.100 TOTAL 100.000

Example 2 Rheological Properties of the Modeling Compound

In this example, the rheological and physical properties of a modelingcompound comprising microspheres F-80DE MICROPEARL® (Sample A) and amodeling compound that do not contain microspheres F-80DE MICROPEARL®(Sample B) were compared.

TABLE 6 Formulation of the modeling compounds Sample A and Sample BSample A Sample B INGREDIENT Weight Percent Weight Percent SODIUMCHLORIDE 6.073 6.085 CALCIUM CHLORIDE 6.073 6.085 ALUM 0.601 0.401POTASSIUM SORBATE 0.300 0.000 SODIUM BENZOATE 0.200 0.201 FLOUR 30.03034.509 C-GEL 04230, WAXY MAIZE 2.336 6.061 STARCH PEGOSPERSE ® 1500MS0.000 0.495 DIFUNCTIONAL BLOCK 1.201 0.000 CO-POLYMER SURFACTANT F-80DEMICROPEARL ® 0.601 0.000 VEGETABLE OIL 1.668 0.000 MINERAL OIL 1.6682.840 WATER 49.216 43.290 FRAGRANCE 0.033 0.033 TOTAL 100.000 100.000

Various properties of the modeling compounds were evaluated by means andmethods described herein.

Viscosity

In some embodiments, a Rheometer was used to measure viscosity of boththe instant modeling compound (Sample A) and a modeling compound that donot contain microspheres (Sample B). The Rheometer is a rotational speedand stress controlled Rheometer. Measuring material filled the spacebetween the bottom stationary plate and the upper rotating cone and flowbehaviour was measured. Viscosity measurements were recorded in Pas*secat changing Shear Rates (1/sec) at controlled Shear Stress. The testconformed to DIN 53018 and the measurements were done at 22° C. Theresults were plotted as viscosity curve in which flow characteristicswere recorded over a range of shear rate (FIG. 1). As shown in FIG. 1,the viscosity as measured in Pascal second [Pas*s] of Sample B is higherthan viscosity of Sample A at changing sheer rates D measured in sec⁻¹[1/s].

The effect of the concentration of surfactant in the modeling compoundwas studied. Modeling compounds having 0, 1.2, 2.4 and 3.5 percentweight of difunctional block co-polymer surfactant and having the sameconcentration of starch-based binder, retrogradation inhibitor andmicrospheres were prepared. Viscosity of each sample was measured asdescribed above. The results were plotted in FIG. 2 as viscosity curvein which flow characteristics were recorded over a range of shear rate.As shown in FIG. 2, the modeling compound comprising 1.2% difunctionalblock co-polymer surfactant had a viscosity of about 323 Pas*s ascompared to 942 Pas*s for the same compound which did not include thesurfactant.

Texture Analysis

The texture of the instant modeling compound (Sample A) and of Sample Bwas measured using a texture Analyzer. Texture Analyzer can be operatedin either compression or tension modes. The compression mode was used totest the hardness or viscoelastic properties of Sample A and Sample B.In compression mode, the probe was moved down slowly at pretest speeduntil a threshold value (the trigger) is reached (5 g). The probe thenwas moved a set distance (10 mm) at a set speed (0.5 mm/sec) into thesample material that was placed and fixed on the base table. Thedeformation force was continuously monitored as a function of both timeand distance until the probe again returned to its starting position.The Max Force was recorded at the 10 mm distance. The Max Force ofSample B was found to be about 417.65 g, whereas the Max Force of SampleA was found to be about 289.3 g. Based on the texture analysis theinstant modeling compound was found to be 1.44 times softer than SampleB.

Extrusion

The extrusion rate and extrusion time was measured by pushing themodeling compounds through a nozzle and the amount of time and extrusionrate were measured for both Sample A and Sample B. The average extrusionrate of Sample A was about 2.9215 gram/sec, whereas the averageextrusion rate for Sample B was about 0.6350. Based on the extrusiondata, Sample A is 4.6 times easier to extrude than Sample B.

Effect of Drying on the Appearance of the Modeling Compounds

FIG. 3 shows a picture of two molded shapes having a dimension of 6×4×2cm molded using Sample A and Sample B. The molded shapes were dried for48 hours at room temperature. As shown in FIG. 3, the molded shape madewith Sample B shows cracks that are not apparent in the molded form madewith the modeling compound disclosed in the present disclosure.

The disclosure has been described with reference to particular preferredembodiments, but variations within the spirit and scope of thedisclosure will occur to those skilled in the art. It is noted that theforegoing examples have been provided merely for the purpose ofexplanation and are in no way to be construed as limiting of the presentdisclosure. While the present disclosure has been described withreference to exemplary embodiments, it is understood that the words,which have been used herein, are words of description and illustration,rather than words of limitation. Changes may be made, within the purviewof the appended claims, as presently stated and as amended, withoutdeparting from the scope and spirit of the present disclosure in itsaspects. Although the present disclosure has been described herein withreference to particular means, materials and embodiments, the presentdisclosure is not intended to be limited to the particulars disclosedherein; rather, the present disclosure extends to all functionallyequivalent structures, methods and uses, such as are within the scope ofthe appended claims.

All patents, patent applications, and published references cited hereinare hereby incorporated by reference in their entirety. While themethods of the present disclosure have been described in connection withthe specific embodiments thereof, it will be understood that it iscapable of further modification. Furthermore, this application isintended to cover any variations, uses, or adaptations of the methods ofthe present disclosure, including such departures from the presentdisclosure as come within known or customary practice in the art towhich the methods of the present disclosure pertain, and as fall withinthe scope of the appended claims.

What is claimed is:
 1. A modeling composition comprising a starch-basedbinder, water, a retrogradation inhibitor and about 20 to about 25percent by volume of microspheres, wherein the microspheres havedensities ranging from 0.022 to 0.2 g/cc.
 2. The modeling composition ofclaim 1, further comprising a surfactant.
 3. The modeling composition ofclaim 2, further comprising a lubricant, a salt, and a preservative. 4.The modeling composition of claim 1, wherein the microspheres areselected from the group consisting of pre-expanded microspheres, glassmicrospheres, and some combination thereof.
 5. The modeling compositionof claim 1, wherein the microspheres have a size ranging from about 90micron to about 130 microns.
 6. The modeling composition of claim 1,wherein the starch-based binder comprises gelatinized starch.
 7. Themodeling composition of claim 3, wherein the salt is selected from thegroup consisting of sodium chloride, calcium chloride, potassiumchloride and some combination thereof.
 8. The modeling composition ofclaim 3, wherein the lubricant is selected from the group consisting ofmineral oil, vegetable oil, triglycerides and some combination thereof.9. The modeling composition of claim 1, wherein the retrogradationinhibitor comprises amylopectin.
 10. The modeling composition of claim1, wherein the retrogradation inhibitor is selected from the groupconsisting of waxy corn starch, waxy rice starch, waxy potato starch andsome combination thereof.
 11. The modeling composition of claim 2,wherein the surfactant is selected from the group consisting ofpolyethylene glycol esters of oleic acid, polyethylene glycol esters ofstearic acid, polyethylene glycol esters of palmitic acid, polyethyleneglycol esters of lauric acid, ethoxylated alcohols, block co-polymer ofethylene oxide, block co-polymer of propylene oxide and some combinationthereof.
 12. The modeling composition of claim 1, wherein thestarch-based binder is selected from the group consisting of wheatflour, rye flour, rice flour, tapioca flour and some combinationthereof.
 13. The modeling composition of claim 3, wherein thepreservative is selected from the group consisting of calciumpropionate, sodium benzoate, potassium sorbate, methyl paraben, ethylparaben, butyl paraben and some combination thereof.
 14. The modelingcomposition of claim 2, wherein the surfactant has a HLB ranging fromabout 1 to about
 7. 15. A modeling composition comprising a starch-basedbinder, water, a retrogradation inhibitor and about 20 to about 25percent by volume of microspheres, wherein the microspheres havedensities ranging from 0.025 to 0.25 g/cc.
 16. A modeling compositioncomprising: (a) about 30% to about 60% by weight water; (b) about 20% toabout 40% by weight starch-based binder; (c) about 0.5% to about 4.0% byweight surfactant; (d) about 0.5% to about 5% by weight retrogradationinhibitor; and (e) about 0.15% to about 1.2% by weight microspheres. 17.The modeling composition of claim 16, wherein the microspheres havedensities ranging from 0.022 to 0.2 g/cc.
 18. The modeling compositionof claim 16, wherein the microspheres have densities ranging from 0.025to 0.25 g/cc.
 19. The modeling composition of claim 16, wherein themicrospheres occupy from about 20 to about 25 percent of the volume ofthe modeling composition.
 20. The modeling composition of claim 16,wherein the surfactant is selected from the group consisting ofpolyethylene glycol esters of oleic acid, polyethylene glycol esters ofstearic acid, polyethylene glycol esters of palmitic acid, polyethyleneglycol esters of lauric acid, ethoxylated alcohols, block co-polymer ofethylene oxide, block co-polymer of propylene oxide and some combinationthereof.
 21. The modeling composition of claim 16, further comprising:(f) about 2.0% to about 5.0% by weight lubricant; (g) about 5% to about20% by weight salt; (h) about 0.1% to about 1% by weight preservative;(i) 0% to about 1% by weight hardener; (j) 0% to about 10% by weighthumectant; (k) 0% to about 0.5% by weight fragrance; and (l ) 0% toabout 3.5% by weight colorant.
 22. The modeling composition of claim 21,wherein: the lubricant is selected from the group consisting of mineraloil, vegetable oil, triglycerides and some combination thereof; thepreservative is selected from the group consisting of calciumpropionate, sodium benzoate, potassium sorbate, methyl paraben, ethylparaben, butyl paraben and some combination thereof; and the hardener isselected from the group consisting of sodium aluminum sulfate, potassiumaluminum sulfate, aluminum ammonium sulfate, aluminum sulfate, ammoniumferric sulfate and some combination thereof.